NAVSEA S9245-AR-TSM-010-PROP

NAVSEA S9245-AR-TSM-010/PROP

0910-LP-012-5880 FIRST REVISION

TECHNICAL MANUAL

MARINE PROPELLER INSPECTION,

REPAIR AND CERTIFICATION

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS (ADMINISTRATIVE/OPERATIONAL USE) (31 MARCH 1997). OTHER REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NAVSEA (03Z5)

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF

CONTENTS OF THE DOCUMENT.

THIS MANUAL SUPERSEDES NAVSEA S9245-AR-TSM-010/PROP

ISSUED 31 MAY 1988

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

FOR OFFICIAL USE ONLY

THIS PAGE INTENTIONALLY LEFT BLANK

NAVSEA S9245-AR-TSM-010/PROP

0910-LP-012-5880 FIRST REVISION

TECHNICAL MANUAL

MARINE PROPELLER INSPECTION,

DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS (ADMINISTRATIVE/OPERATIONAL USE) (31 MARCH 1997). OTHER REQUESTS

FOR THIS DOCUMENT SHALL BE REFERRED TO NAVSEA (03Z5)

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF

CONTENTS OF THE DOCUMENT.

THIS MANUAL SUPERSEDES NAVSEA S9245-AR-TSM-010/PROP

ISSUED 31 MAY 1988

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

FOR OFFICIAL USE ONLY

31 MARCH 1997

NAVAL 5HIf' SY51EMS

ENGIN Ef;~INca STATION

PHILADELPHIA, PI; 19r1~-508:1

DEPARTMENT OF THE NAVY

NAVAL SUFI FACE W/'.RF'AF'lE CE:N~ER

CAAOEROCK 01V1510N

Ser9323/078 q (\ 2nO3~V lU From: C°.mmand~. Carderock Di"ision. Naval Surface Warfare Center ~' '\t

Philadelphia, PA 19112-5083 fAI.

To: Distribution

S UBJ: B..4LANCE REQUIRE1\IlENTS

(a) NA VSEA S9245-AR- TSM-Ol0/PROP. First Revision. TechnicalManua1, Marine Propeller Inspection. Repair and Certification

(1) Balance Inspection Requirements dtd 16 May 03

1.. Purpos~: To provide interim balancerequircments until reference (a) is revised.

2. S_C;QP~... This letter applies to all propellers, propeller caps, deVices, tailcones orcon1TOllable pitch propeller (CPP) blade sets balanced in accordance with reference (a).

3. Background. Balance is a critical process TO ensure satisfactory performance ofpropellerst propeller caps, devices, tail cones or CPP blade sets in service. Reference (a), section 5-7.2 contains the requirements for balance inspection.

4. Action. Replace section 5-7.2 of reference (a) with enclosure (1).

5 Questions concerning this subject can be directed to Ms..JoanMessick, NSWCCD-SSES 9323 215-897~7374, or email rnessickoe 1nswccd.na omjl

~.;tJ ..I8~

M..S. BOUVE

By direction

Distribution:

COMSUBLANT (CodeN4, 402) COMSUBPAC (Code N4, 402) COMNA VSEASYSCOM (Code 05H, 05M. 05,08, 07T, 392, 392A)

DCMA W -OCT A (SPT)

DCMA SEATTLE (Code GWTA) FTSCLANT (Code 523, 4312) FTSCP AC (Code 760. 302) NAVICP 05822.07 (G. Clippinger)

NAVSEA DET (SUBMEPP)

NAVSHIPYDNORVA

NA VSHIPYD PEARL

NA VSHIPYD PTSMH

SUBJ: BAL.4.NCE REQlliREl\'lENTS

Distribution (continued)

NAVSHIPYDPUGET

SUPSHlP GROTON

SUPSHIP NEV\!~ORTNEWS

SUPSHIP PORTSMOUTH

SUPSHIP SAN DIEGO

SUPSHIP PUGET SOUND

SUPSHIP JACKSONVILLE

NAVSHIPREPFACSASEBO

NA VSHIPREPFAC YOKOSUKA

NAVSHIPYD NOR V A DET NFPC

CDNS\VC BETHESD"I\ (Code 522X) IMF BAJ"1GOR (Code 400, 302) TRIREFF AC KINGS BAY (Code 400. 302)

SUBASE NLON

SUBASE SAN DIEGO

CONSUBRON ONE

CONSUBRONTHREE

CO CONSLLillATED DIVERS UNIT (SAN DIEGO) NE\VPQRT NEWS SHIPBUll-DINGANDDRYDOCK CO..

W ARTSILA~LIPS PROPELLER CO. CHESAPE.A.KE VA

W ARTSILA-LIPS PROPELLER CO. POULSBOW A

PACIFIC MARINE PROPELLERS CO.. SAN DIEGO

ROLLS ROYCE NAVAL MARINE CO. P ASCAGOULA MS

ROLLS ROYCE NAVAL MARINE CO. WALPOLEMA

JOHNSONS SHIP PROPELLER CO. PORTSMOUTH V A

DCMA QAR c/o JOHN CRANE-LIPS PROPELLER CO. CHESAPEAKE VA DCMA QARc/o 10HNCRANE-LIPS PROPELLER CO.POULSBO W A DCMA QAR c/o PACIFIC MARINE PROPELLERS CO. SAN DIEGO CA DCMA QAR c/o ROLLS ROYCE NA V ALMARINE P ASCAGOULA MS DCMA QAR c/o ROLLS ROYCE NAV ALMARINE PORTSMOUTH VA DCMA QAR c/o JOHNSONS SHIP PROPELLER CO. PORTSMOUTH V A

Copy to:

NSWCCD-SSES 932/8. 9J23, 93234

Writer: J. Messick, 93234, X7374 Typist: C. Catagno. 9328, 19 May 03

Balance Inspection Requirements

5/16/03

5-7.2 BALANCE INSPECTION. Propellers, propeller caps, devices, tailcones, or CPP blade sets shall be staticaJly (single pl.ane) balanced on dynamic (rotating) balancing equipment., Balancing shall be performed after manufacture or repair is complete with eyebolt hole plugs installed. CPP btadesets shall be balanced as a complete blade set on a dummy hub that meets the design requirements for installed radial position, angular spacing and design pitch- Propeller caps, devices or tailcones shall be balanced after the installation of syntactic foam and cover plate, if applicable.

5-7.2.1 Weight. For monoblocprope.llers, record the propelferweight from the stamped hub data. For CPP blade sets. measure and record the actual weight of the individual blades with and without palm weight, and the balance fixture (dummy hub) with all attachment hardware (bolts, adapter plates, etc.). For propeller caps, devices or tailcones, measure and record the actual weight. of the cap with syntactic foam and coverplate installed, if app.licable.

5-7.2.2 Recording of Results.. The magnitude of all unbalance measurements shall be recorded in ounce-inches. The angular location of an unbalance measurements shall be recorded in degrees as an angle from the BCA of btade 1 in the direction of propeller rotation. For propeller caps, devices or tailcones, the angular location shall be recorded from the plane of the s.ide eyebolt hole in the right hand direction of rotation.

5-7.2.3 Arignment. The propeller, propeller cap.. device, tailcone or CPP blade set center line (axis of rotation) and the balance machine center line (axis of rotation) shall be aligned by means of a mandrel or dummy hub. For monobloc propellers balanced with the propel1.er center tine oriented vertically I two concentric rings may be used as a mandrel with one located on the forward land and one located on the aft land of the bore. Tapered mandrel or concentric ring surfaces shall match the monobloc propeller bore, contact a minimum of two inches of each bore land and shall be rigid enough to resist deflection. Alignment of the propeller to the balance machine with the mandrel, dummy hub or installed concentric rings sha.ll meet. therunout requirements of 5-7.2.4.1

The ma ndrel or dummy hub shall be5-7.2.4 Mandrel or Dummy Hub Inspection inspected as follows:

ENCL (,)

5-7.2.4.1 The runout(TIR) ofihe mandrel or dummy hub shall be Inspected and corrected, if necessary, prior to measuring the residual unbalance of the propelfer. The position of the dummy hub faces or adapter plates, if used, shall meet the specified runout requirements for radial position. The maximum allowabfe TIR of the mandrel, installed concentric rings, or dummy hub shall be determined as follows:

where: TIR

Ur

- total indicated runout (in inches);

propeller residual unbalance tolerance (in ounce-inches) as specified on the propeller drawing;

propeller weight (in pounds).w =

For cpr bi.ade sets, the total weight (W) includes the dummy hub and the sum of individual blade weights without palm weight.

For propeller caps, devices or tailcones the total weight (W) includes the propeller cap, device or tailcone and the mandrelw1th all attachment hardware.

Measure and record the TIR of the mandrel, instaHedconcentric rings, or dummy hub.

5-7.2.4.1.1 The eccentricity of the inside and outside diameter of concentric rings shall be measured and recorded. The eccentricity between the inside andoutsldediameter of concentric rings shall not exceed one half of the allowable TIR or 0.001 inch, whichever is less.

5-7.2.4.2 The maximum allowable residual unbalance of the mandrel or dummy hub shall be determined as follows:

UM=O.OO5CUT)

where: UM - residual unba.lance (in ounce-inches) of the mandrel or CPP dummy hub;

prope11er residual unbalance tolerance (in ounce-inches) as specified on the propeller drawing, Ur =

Mandrels. concentric rings or dummy hubs sha11 be balanced with all attachment hardware (adapter plates, bolts. etc.). Measure and record the unbatance of the mandrel or dummy hub.

5-7.2.4.3 For CPP blade sets.. the angular spacing of the dummy hub blade positions shall be within 0.25 degrees of design and the pitch of the dummy hub dowel pins shall be within. 0.50 percent of design.

5-7.2.5 Component Balance. Measure and record the magnitude (U1) and angle (Y1) of residual unbalance of the propeller, propeller cap, device. tallcone or CPP blade set

Rotate the propeller, propeller cap, device or tailcone 180 degrees on the balance mandrel after completion of the first balance inspection operation. Alternatively, CPP blade sets mounted on a dummy hub attached to a mandrel may be shifted two positions, maintaining the blade numbering sequence.. CPP blade, propeller cap, device or tailcone attachment hardware shall not be shifted between the two balance inspection operations.. Measure and record the magnitude (U2) and angle (12) of residual unbalance of the propeller, propeller cap, device, tallcone or CPP blade set for the second balance inspection operation..

5-7.2.6 Sensitivity Inspection. The sensitivity of the balance machine shall be inspected after the second balance inspection operation. A sensitivity weight (ws) shall be placed at an approprIate radial distance (r) as follows:

w r where Ws r

UT

- sensitivity weight (in ounces);

radial location of the weight (in inches);

propel/.er residual unbalance tolerance (in ounce-inches) as specified on the propeller drawing.

The weight shall be within 0.5 ounces of the calculated value and located at the heaviestanguJar location (Yz) within +/-.2 degrees. The location of the weight may be divided between two blades to achieve the required angular position. Record the weight(s) in ounces~ the radial position in inches and the angular location(s) of the sensitivity weight{s). The addition of the sensitivity weight shall be detected by the ba1ance machine. Measure and record the magnitude (3) and angle (0) of residual unbalance of the propeller. propeller cap, device, tailcone or CPP blade set with the sensitivity weight added. Determine and record the expected magnitude of unbalance as follows:

E=U + (O.IPr

Ewhere =

U2 =

UT

expected residual unbalance (in ounce~inches) of the sensitivity inspection;

residual unbalance (in ounce-inches) of the second balance inspection operation;

propeller residual unbalance tolerance (in ounce-inches) as specified on the propeller drawing.

5-7.2.7 Acceptance Criteria. The following acceptance criteria sha11 be app1ied to the data acquired i'n 5-7.2.5 through 5-7.2.6:

A.

B..

C

U, and Uz shall not exceed 0.75 UTi

The difference between Sand Eshall not exceed 0.O5UT.

The difference between Yz and e shall not exceed 20 degrees.

S9245-AR-TSM-010/PROP

LIST OF EFFECTIVE PAGES

Date of issue for original pages:

Original . . . 0 . . . 31 March 1997 Total number of pages in publication is 116 consisting of the following:

Page Change No. No.

Title and A Change Record Change Record-blank. 0 Certification Certification-blank i through vii viii blank 1-1 through 1-3 1-4 blank 2-1 through 2-2 3-1 through 3-16 4-1 through 4-30 5-1 through 5-30 6-1 through 6-5 6-6 blank ………………0 7-1 through 7-6 8-1 through 8-6 9-1 through 9-2

A

CHANGE RECORD

Change No.

Date Title and/or

Brief Description Signature of

Validating Officer

Change Record/(Change Record-blank)

This page intentionally left blank

TABLE OF CONTENTS

TECHNICAL MANUAL, MARINE PROPELLER, INSPECTION,

Chapter/Paragraph Page 1 SCOPE................................................................................................................ 1-1

1-1 GENERAL ........................................................................................................... 1-1 1-2 SUPERSEDURE TO DRAWING REQUIREMENTS........................................... 1-1 1-2.1 THREAD CLASS................................................................................................. 1-1 1-2.2 REPLACEMENT EYEBOLT HOLE PLUGS........................................................ 1-1 1-2.3 REPLACEMENT FILL AND VENT HOLE PLUGS .............................................. 1-1 1-2.4 REPLACEMENT STUDS .................................................................................... 1-2 1-3 REFERENCES.................................................................................................... 1-2 1-4 POINTS OF CONTACT....................................................................................... 1-3

2 INTRODUCTION................................................................................................. 2-1 2-1 GENERAL ........................................................................................................... 2-1 2-2 PROPELLER INSPECTIONS ............................................................................. 2-1 2-3 PROPELLER REPAIR ........................................................................................ 2-1 2-4 PROPELLER CERTIFICATION .......................................................................... 2-1 2-4.1 DEFINITION........................................................................................................ 2-1 2-4.2 CERTIFICATION PROCEDURE......................................................................... 2-2 2-4-3 RELEASE OF PROPELLER ............................................................................... 2-2 2-4.4 DOCUMENT DISTRIBUTION ............................................................................. 2-2 2-5 INSPECTION FORM DISTRIBUTION ................................................................ 2-2

3 PROPELLER TERMINOLOGY ........................................................................... 3-1 3-1 TERMINOLOGY.................................................................................................. 3-1 3-1.1 BLADE CENTER AXIS (BCA)............................................................................. 3-1 3-1.2 BLADE CENTERLINE (BCL) .............................................................................. 3-1 3-1.3 BLADE NUMBERING.......................................................................................... 3-1 3-1.4 BLADE SECTION HALF WIDTH......................................................................... 3-1 3-1.5 BLADE SECTION WIDTH................................................................................... 3-1 3-1.6 CYLINDRICAL CENTER ELEMENT (CCE)........................................................ 3-1 3-1.7 CYLINDRICAL SECTION (BLADE SECTION) ................................................... 3-1 i

3-1.8 CYLINDRICAL SECTION STATIONS................................................................. 3-1 3-1.9 FILLETS .............................................................................................................. 3-2 3-1.10 LEADING EDGE (LE).......................................................................................... 3-2 3-1.11 LEADING EDGE ORDINATE.............................................................................. 3-2 3-1.12 LEFT HAND PROPELLER.................................................................................. 3-2 3-1.13 OFFSETS............................................................................................................ 3-2 3-1.14 PITCH ................................................................................................................. 3-2 3-1.15 PITCH ANGLE .................................................................................................... 3-2 3-1.16 PITCH LINE (PL)................................................................................................. 3-2 3-1.17 PORT .................................................................................................................. 3-2 3-1.18 PRESSURE FACE (PF) ...................................................................................... 3-2 3-1.19 PROPELLER CENTER AXIS (PCA) ................................................................... 3-2 3-1.20 PROPELLER CENTERLINE (PCL)..................................................................... 3-3 3-1.21 RAKE .................................................................................................................. 3-3 3-1.22 REFERENCE PLANE ......................................................................................... 3-3 3-1.23 RIGHT HAND PROPELLER ............................................................................... 3-3 3-1.24 SKEW.................................................................................................................. 3-3 3-1.25 STANDOFF......................................................................................................... 3-3 3-1.26 STARBOARD (STBD) ......................................................................................... 3-3 3-1.27 SUCTION FACE (SF).......................................................................................... 3-4 3-1.28 THICKNESS........................................................................................................ 3-4 3-1.29 TRACK ................................................................................................................ 3-4 3-1.30 TRAILING EDGE (TE)......................................................................................... 3-4 3-1.31 TRAILING EDGE ORDINATE ............................................................................. 3-4

4 PROPELLER INSPECTION GAGES .................................................................. 4-1 4-1 TYPES AND FUNCTIONS OF GAGES .............................................................. 4-1 4-1.1 CYLINDRICAL GAGES....................................................................................... 4-1 4-1.2 EDGE GAGES .................................................................................................... 4-2 4-1.3 TIP GAGES......................................................................................................... 4-2 4-1.4 NORMAL FILLET GAGE ASSEMBLY ................................................................ 4-2 4-1.5 RADIAL FILLET GAGE ....................................................................................... 4-3 4-1.6 TIP PROFILE (PLANFORM) GAGE.................................................................... 4-3 4-1.7 PLUG GAGE ....................................................................................................... 4-3 4-1.8 SPECIAL GAGES ............................................................................................... 4-3 4-2 BLADE DIVISIONS FOR USING GAGES........................................................... 4-4 4-2.1 CYLINDRICAL SECTION.................................................................................... 4-4 4-2.2 RADIAL DIVISIONS FOR NORMAL FILLET GAGES......................................... 4-4 4-3 GAGE APPLICATION ......................................................................................... 4-4 ii

4-3.1 EQUIPMENT....................................................................................................... 4-4 4-3.2 POSITION OF PROPELLER............................................................................... 4-5 4-3.3 LOCATION OF CYLINDRICAL SECTIONS........................................................ 4-5 4-3.4 APPLICATION OF PRESSURE FACE CYLINDRICAL GAGES......................... 4-5 4-3.5 APPLICATION OF SUCTION FACE CYLINDRICAL GAGES ............................ 4-6 4-3.6 APPLICATION OF EDGE GAGES...................................................................... 4-7 4-3.7 APPLICATION OF NORMAL FILLET GAGE ASSEMBLIES .............................. 4-7 4-3.8 APPLICATION OF THE RADIAL FILLET GAGE ................................................ 4-8

4-3.9 LOCATION OF BLADE CENTERLINE AND TIP USING

CYLINDRICAL GAGES.................................................................................... 4-8 4-3.10 APPLICATION OF TIP GAGES .......................................................................... 4-9 4-3.11 APPLICATION OF TIP PROFILE (PLANFORM) GAGE..................................... 4-9 4-3.12 APPLICATION OF PLUG GAGES .................................................................... 4-10 4-3.13 APPLICATION OF FAIRING ROD .................................................................... 4-10 4-3.14 APPLICATION OF SPECIAL GAGES............................................................... 4-10

5 PROPELLER INSPECTION................................................................................ 5-1 5-1 PROPELLER INSPECTION................................................................................ 5-1 5-2 PROPELLER GAGES......................................................................................... 5-1 5-2.1 TYPES OF GAGES............................................................................................. 5-1 5-2.2 PREREQUISITES ............................................................................................... 5-1 5-2.3 INSPECTION OF GAGES................................................................................... 5-1 5-2.4 HANDLING, STORING, AND SHIPPING GAGES.............................................. 5-2 5-3 PROPELLER VISUAL INSPECTION .................................................................. 5-2 5-3.1 VISUAL PRESERVATION INSPECTION ........................................................... 5-2 5-3.2 VISUAL TECHNICAL INSPECTION ................................................................... 5-3

5-4 PROPELLER PREREPAIR/FINAL DIMENSIONAL INSPECTION ..................... 5-3

5-4.1 APPLICABILITY .................................................................................................. 5-3 5-4.2 ACCURACY ........................................................................................................ 5-4 5-4.3 DOCUMENTATION............................................................................................. 5-4 5-5 PRESSURE FACE INSPECTIONS..................................................................... 5-4 5-5.1 PROPELLER POSITION AND PREPARATION ................................................. 5-4 5-5.2 PRESSURE FACE RADIUS LINES .................................................................... 5-4

5-5.3 PRESSURE FACE INSPECTIONS USING CYLINDRICAL GAGES.................. 5-4

5-5.4 SKEW INSPECTION........................................................................................... 5-7 5-5.5 PRESSURE FACE EDGE CONTOUR INSPECTION......................................... 5-8 5-5.6 PRESSURE FACE TIP CONTOUR INSPECTION ............................................. 5-8

5-5.7 PRESSURE FACE HUB AND FILLET CONTOUR INSPECTION...................... 5-9

5-5.8 PRESSURE FACE FAIRNESS INSPECTION .................................................... 5-9 iii

5-5.9 BLADE ANGULAR SPACING INSPECTION ................................................... 5-10 5-5.10 PROPELLER RADIUS INSPECTION ............................................................... 5-10 5-5.11 BLOCK AND HUB INSPECTION ...................................................................... 5-10 5-6 SUCTION FACE INSPECTIONS ...................................................................... 5-10 5-6.1 PREPARATION................................................................................................. 5-10 5-6.2 SUCTION FACE RADIUS LINES...................................................................... 5-10

5-6.3 SUCTION FACE INSPECTIONS USING CYLINDRICAL GAGES ................... 5-10

5-6.4 SUCTION FACE EDGE CONTOUR INSPECTION .......................................... 5-11 5-6.5 SUCTION FACE TIP CONTOUR INSPECTION............................................... 5-12 5-6.6 SUCTION FACE HUB AND FILLET CONTOUR INSPECTION........................ 5-12 5-6.7 SUCTION FACE FAIRNESS INSPECTION...................................................... 5-13 5-6.8 BLADE THICKNESS INSPECTION .................................................................. 5-13 5-7 ADDITIONAL INSPECTIONS ........................................................................... 5-13 5-7.1 TIP PROFILE INSPECTION ............................................................................. 5-13 5-7.2 BALANCE INSPECTION................................................................................... 5-13 5-7.3 SURFACE FINISH INSPECTION ..................................................................... 5-15 5-7.4 LIQUID PENETRANT INSPECTION................................................................. 5-15 5-7.5 PRAIRIE AIR SYSTEM INSPECTION .............................................................. 5-15 5-7.6 WELDABILITY DETERMINATION.................................................................... 5-15 5-7.7 PRESSURE TESTS.......................................................................................... 5-15 5-7.8 WELD LOCATION IDENTIFICATION ............................................................... 5-15 5-7.9 HUB BORE INSPECTION................................................................................. 5-15 5-7.10 EYEBOLT AND STUD HOLE INSPECTION..................................................... 5-16 5-7.11 KEYWAY INSPECTION.................................................................................... 5-16 5-7.12 OTHER ATTRIBUTE INSPECTIONS ............................................................... 5-16 5-7.13 ACCESSORY INSPECTION............................................................................. 5-16 5-7.14 CPP BLADE PALM INSPECTION .................................................................... 5-16

6 PROPELLER TOLERANCES ............................................................................. 6-1 6-1 NEW MANUFACTURE ....................................................................................... 6-1

6-2 VISUAL TECHNICAL INSPECTION ACCEPTANCE STANDARDS................... 6-1

6-3 REPAIR............................................................................................................... 6-1 6-3.1 TOLERANCES.................................................................................................... 6-1 6-3.2 NONESSENTIAL TOLERANCES ....................................................................... 6-1 6-3.3 TOLERANCE CLASSES..................................................................................... 6-2 6-3.4 PRAIRIE AIR SYSTEM ....................................................................................... 6-2 6-3.5 PRAIRIE AIR CHANNEL COVER PLATE WELDS............................................. 6-2 6-3.6 THREADED HOLES ........................................................................................... 6-2 6-3.7 CPP BLADE PALM TOLERANCES .................................................................... 6-3 iv

7 ANALYSIS OF DATA .......................................................................................... 7-1 7-1 ANALYSIS OF DATA .......................................................................................... 7-1 7-2 PITCH DEVIATION ............................................................................................. 7-1 7-3 RAKE DEVIATION .............................................................................................. 7-1 7-3.1 RAKE CALCULATION ........................................................................................ 7-1 7-3.2 AVERAGE BLADE CENTER AXIS ..................................................................... 7-2 7-3.3 RAKE DEVIATION .............................................................................................. 7-3 7-3.4 CALCULATION OF “O” AND “Z” VALUES.......................................................... 7-3 7-4 TRACK CALCULATION...................................................................................... 7-4 7-4.1 NEW MANUFACTURE PROPELLERS .............................................................. 7-4 7-4.2 REPAIRED PROPELLERS................................................................................. 7-4 7-5 SKEW DEVIATION ............................................................................................. 7-5 7-6 BLADE ANGULAR SPACING ............................................................................. 7-5

8 PROPELLER REPAIRS...................................................................................... 8-1 8-1 PROPELLER REPAIRS...................................................................................... 8-1 8-1.1 DEFICIENCIES ................................................................................................... 8-1 8-1.2 STRAIGHTENING............................................................................................... 8-1 8-1.3 MATERIAL REMOVAL........................................................................................ 8-1 8-1.4 WELDING............................................................................................................ 8-1 8-1.5 CLEANING.......................................................................................................... 8-1 8-1.6 CAVITATION EROSION ..................................................................................... 8-2 8-1.7 CRACKS ............................................................................................................. 8-2 8-1.8 POROSITY.......................................................................................................... 8-2 8-1.9 THICKNESS AND WIDTH .................................................................................. 8-2 8-1.10 PITCH ................................................................................................................. 8-2 8-1.11 RAKE .................................................................................................................. 8-2 8-1.12 CONTOURS AND FAIRNESS ............................................................................ 8-2 8-1.13 MONOBLOC PROPELLER BALANCING ........................................................... 8-2

8-1.14 CONTROLLABLE PITCH PROPELLER (CPP) BLADE BALANCING................ 8-3

8-1.15 ABNORMAL METHODS OF BALANCING.......................................................... 8-3 8-1.16 PRAIRIE AIR EMITTER SYSTEM ...................................................................... 8-3 8-1.17 STRESS RELIEF ................................................................................................ 8-4 8-1.18 SURFACE FINISH .............................................................................................. 8-4 8-1.19 HOLE REPAIR .................................................................................................... 8-4 8-1.20 CPP DOWEL PIN AND PRAIRIE AIR INLET HOLE........................................... 8-4 8-1.21 BLADE PALM FLATNESS .................................................................................. 8-5 8-1.22 IDENTIFICATION STAMPING ............................................................................ 8-5 v

8-1.23 REPAIR STAMPING ........................................................................................... 8-5

9 PROPELLER PRESERVATION, PACKAGING, HANDLING, STORAGE

AND TRANSPORTATION............................................................................... 9-1 9-1 PROPELLER PRESERVATION AND PACKAGING........................................... 9-1 9-2 PROPELLER HANDLING ................................................................................... 9-1 9-2.1 TURNING............................................................................................................ 9-2 9-3 PROPELLER STORAGE .................................................................................... 9-2 9-4 PROPELLER TRANSPORTATION..................................................................... 9-2 vi

LIST OF ILLUSTRATIONS

Figure Page 3-1 Propeller Construction Lines Showing Zero Rake and Zero Skew .................. 3-5 3-2 Propeller Construction Lines Showing Zero Rake and Positive Skew ............. 3-6 3-3 Propeller Construction Lines Showing Positive Rake and Zero Skew ............. 3-7 3-4 Propeller Construction Lines Showing Positive Rake and Positive Skew........ 3-8 3-5 Orientation and Description of a Cylindrical Section ........................................ 3-9 3-6 Typical Blade Numbering Sequence .............................................................. 3-10 3-7 Example of Stations ....................................................................................... 3-11 3-8 Example of Fillet Area .................................................................................... 3-12 3-9 Orientation of the Pitch and Pitch Helix on a Propeller Blade ........................ 3-13 3-10 Pitch Diagrams Showing Constant and Variable Pitch................................... 3-14 3-11 Example of the Pitch Line and Pitch Angle (α)............................................... 3-15 3-12 Examples of Rake and Track ......................................................................... 3-16 4-1 Typical Cylindrical Gage Layouts and Markings ............................................ 4-11 4-2 Edge Gage Layout and Markings................................................................... 4-12 4-3 General Layout of Tip Gage ........................................................................... 4-13 4-4 Normal Fillet Gage Assembly......................................................................... 4-14 4-5 Radial Fillet Gage........................................................................................... 4-15 4-6 Tip Profile Gage Application........................................................................... 4-16 4-7 Cylindrical Section Layouts ............................................................................ 4-17 4-8 Radial Divisions for Fillet Gages .................................................................... 4-18 4-9 Equipment for Cylindrical Gage Application ................................................... 4-19 4-10 Pressure Face Cylindrical Gage Applied along Scribe Lines ......................... 4-20 4-11 Alignment of LE and TE on Pressure and Suction Face Gages .................... 4-21 4-12 Edge Contour Inspection of Pressure and Suction Faces.............................. 4-22 4-13 Flat Edge Gages Applied on Chord................................................................ 4-23 4-14 Additional Contour Segments Checked with Edge and Tip Gages ................ 4-24 4-15 Hub Gage Planes Perpendicular to the PCL.................................................. 4-25 4-16 Blade Tip Location.......................................................................................... 4-26 4-17 Beta Angle Method of Locating the Blade Tip ................................................ 4-27 4-18 Application of Tip Gage.................................................................................. 4-28 4-19 BCL Development and Tip Gage Application................................................. 4-29 4-20 Tip Profile Gage Application for Repair .......................................................... 4-30 5-1 Reference Plane Locations for Height Measurements of J and K.................. 5-18 5-2 Reference Planes and Measurements for Rake Using Gages....................... 5-19 5-3 Reference Planes and Measurements for Rake Using Axial Projection of vii

BCA................................................................................................................ 5-20 5-4 Reference Planes and Measurements for Rake Using Axial Projection of BCL ................................................................................................................ 5-21 5-5 Reference Planes and Measurements for Rake Using Perpendicular Projection of BCL ........................................................................................... 5-22 5-6 Blade Section Half Width Deviations.............................................................. 5-23 5-7 Measurement for Skew Deviation .................................................................. 5-24 5-8 Inspection Stations on Normal Fillet Gage Assembly .................................... 5-25 5-9 Angular Spacing of Blades............................................................................. 5-26 5-10 Alignment of Suction Face Scribe Lines with Pressure Face Scribe Lines .... 5-27 5-11 Orientation of Calipers for Measuring Blade Thickness ................................. 5-28 5-12 Stud Hole Depth and Effective Thread Length............................................... 5-29 5-13 CPP Blade Palm Attribute Inspections ........................................................... 5-30 7-1 Rake................................................................................................................. 7-6 8-1 Stud Hole Repair .............................................................................................. 8-6

LIST OF TABLES

Table Page 5-1 Propeller Inspections ..................................................................................... 5-17 6-1 Repair Tolerances............................................................................................ 6-4 viii ix

CHAPTER 1

SCOPE

1-1 GENERAL

This manual specifies the requirements and provides the information necessary to inspect, repair, certify, and handle marine propellers. Information is also included on procedures and equipment for inspection and repair.

Additional requirements, repair procedures, and inspections for specific marine propellers are identified in these documents:

Controllable pitch propellers (CPP) - Class specific Technical Repair Standards (TRS).

Submarine propellers/propulsors - NAVSEA S9245-AQ-TSM-010/PROP, Technical Manual

Propeller Assembly and Repair; and applicable manufacturing drawings.

SSN 21 Class propulsors - NAVSEA S9245-AW-MMA-010/(V), Maintenance Manual; and

NAVSEA drawing Nos. 245-6520270 and 245-6676151.

Manganese bronze, Nickel-manganese bronze, and Manganese-nickel-aluminum bronze propellers - DOD-STD-2185(SH), Requirements for Repair and Straightening of Bronze Naval Ship Propellers.

Devices - Applicable manufacturing and gage drawings.

1-2 SUPERSEDURE TO DRAWING REQUIREMENTS

1-2.1 THREAD CLASS. Replacement eyebolts for propellers and caps, propeller hub eyebolt hole plugs, propeller cap eyebolt hole plugs, gland studs and nuts, and propeller cap studs and nuts shall be manufactured with a Class 2 fit thread which supersedes Class 3 fit threads specified on some drawings.

1-2.2 REPLACEMENT EYEBOLT HOLE PLUGS. Replacement eyebolt hole plugs for propellers and caps shall be manufactured from reference (P), POM 130 B44350, material in accordance with the configuration on the applicable propeller or cap drawing. In addition, a 1/8 inch diameter vent hole shall be drilled through the plug on its longitudinal axis as shown on reference (Q).

1-2.3 REPLACEMENT FILL AND VENT HOLE PLUGS. Replacement fill and vent hole pipe plugs for propeller hubs and caps shall be manufactured from reference (P), POM 130 B44350, material.

1-1

1-2.4 REPLACEMENT STUDS. Replacement gland and cap studs shall be continuous all thread design in accordance with reference (Q). Thread sizes and stud lengths shall be as specified on the applicable propeller drawing.

1-3 REFERENCES

The current revision of these references shall be used unless otherwise specified.

A. NAVSEA S9245-AP-TSM-010/PROP, Manual of Instructions for Design of Marine Propeller

Blade Gages.

B. NAVSEA S9243-A5-MMD-010, Gages, Plug and Ring, Propellers and Propulsion Shafting;

Repair, Inspection, Certification and Use.

C. International Standard ISO 9002, Quality Systems - Model for Quality Assurance in

Production, Installation and Servicing.

D. NAVSEAINST 9245.1A, Ship Propellers and Propulsion Shafts; Procedures for Maintaining.

E. NAVSEA S9245-AQ-TSM-010/PROP, Technical Manual Propeller Assembly and Repair.

F. Military Standard DOD-STD-2185(SH), Requirements for Repair and Straightening of Bronze

Naval Ship Propellers.

G. Military Specification MIL-P-2845, Packaging of Main Propulsion Shafting, Bearing, Boat and

Ship Propellers, and Associated Repair Parts.

H. NAVSEA 9245/7, Propeller Visual Inspection.

I. NAVSEA 9245/8, Propeller Dimensional Inspection.

J. NAVSEA 9245/9, Propeller Certification.

K. NAVSEA 9245/11, Propeller Blade Gage Visual Inspection.

L. NAVSEA 9245/13, Propeller Blade Gage Dimensional Inspection.

M. NAVSEA 9245/14, Propeller Blade Gage Certification.

N. Military Standard MIL-STD-2035(SH), Nondestructive Testing Acceptance Criteria.

O. Military Specification DOD-P-24562, Propellers, Ship, Controllable Pitch.

1-2

P. ASTM D4181, Standard Specification for Acetal (POM) Molding and Extrusion Materials.

Q. NAVSHIPS Dwg. No. 803-4435837, Propeller Standard Drawing.

R. Military Standard MIL-STD-167, Mechanical Vibrations of Shipboard Equipment.

S. Naval Ships Technical Manual, Chapter 245.

T. Military Standard MIL-STD-271, Requirements for Nondestructive Testing Methods.

U. Military Standard MIL-STD-278, Fabrication Welding and Inspection; and Casting Inspection and Repair for Machinery, Piping and Pressure Vessels.

V. NAVSEA SL460-AA-HBK-010, Handbook for Inspection, Packaging, Handling, Storage and

Transportation.

1-4 POINTS OF CONTACT

Nontechnical: Inventory - NAVICP 05121;

Nontechnical: Financial - NAVSEA 03F;

Technical - NSWCCD-SSES, Philadelphia, 9323.

1-3

1-4

CHAPTER 2

INTRODUCTION

2-1 GENERAL

Propellers shall conform to the design hydrodynamic contours. For both new manufacture and repair, the critical hydrodynamic contours and geometry shall be held within specified tolerances. Propellers are classified as Class I, II, III or IV depending on operating requirements. Specific tolerances apply to each class. Section 6-3.3 identifies the ship classes included in each propeller class. For inspection, repair and certification of Class IV propellers, the following applies:

A. A certification document is not required;

B. Qualified inspectors are not required;

C. NSWCCD-SSES approval of inspection reports is not required;

D. Repair and inspection does not have to be done by a qualified activity.

2-2 PROPELLER INSPECTIONS

This manual provides the technical guidance and procedures used to inspect propellers. Propeller inspection gage description and application are included. Details of propeller blade gage design and dimensional inspection are in reference (A). Details of propeller plug gage design and dimensional inspection are in reference (B). Details of propeller visual (preservation and technical) and dimensional inspections are in sections 5-3 and 5-4 of this manual. An inspection system in accordance with reference (C), unless otherwise specified by contract, shall be used for propeller dimensional inspection.

Reference (D) includes instructions on when propeller visual and dimensional inspections shall be performed. For submarine propellers, additional requirements, repair procedures and inspections are specified in reference (E).

2-3 PROPELLER REPAIR

Repair procedures are defined briefly and appropriate references are identified for more detailed repair procedures, which shall be developed by each repair activity.

2-4 PROPELLER CERTIFICATION

2-4.1 DEFINITION. A certified propeller is classified as Condition A or Ready-For-Issue (RFI).

Certification requires that the following conditions be fulfilled:

A. The propeller conforms to specifications, which are the applicable propeller drawing, this manual, and reference (E) when applicable;

B. Satisfactory visual technical inspection results;

C. Government approved waivers and deviations, which shall be recorded on the certification

2-1 document.

2-4.2 CERTIFICATION PROCEDURE. Certification is required of all propellers upon completion of manufacturing or repair work to ensure that the propeller meets specifications. The certification procedure is as follows:

2-4.2.1 For propellers undergoing repair, visual and dimensional prerepair inspections shall be performed and reports submitted to the contracting activity along with proposed repairs and deviation requests (if needed).

2-4.2.2 Upon completion of manufacturing or repairs, final visual technical and dimensional inspections of the propeller shall be performed and the final reports and propeller certification document submitted to the contracting activity. Stress relief documentation (e.g., graphical or tabulated thermocouple temperature recordings, thermocouple locations, etc.), when required by reference (F), shall be included.

Before submittal, the final report shall be reviewed to ascertain that all required inspections have been performed and that the results meet specified tolerances, except as exempted by waivers and deviations which have been approved by the contracting activity. Propellers shall be certified only by qualified personnel who have satisfactorily completed the Propeller Certification Course or persons designated by

NAVSEA.

2-4.3 RELEASE OF PROPELLER. Although a propeller may be certified by qualified personnel, it shall not be shipped until the contracting activity reviews and approves the final visual technical and dimensional inspection reports. When specifications have not been met and waivers or deviations have been requested, the propeller shall not be certified or shipped until the contracting activity approves all waiver and deviation requests.

2-4.4 DOCUMENT DISTRIBUTION. The contracting activity shall send a copy of the final approved visual technical inspection report, dimensional inspection report, and certification document to

NSWCCD-SSES.

2-5 INSPECTION FORM DISTRIBUTION

Requirements for submitting propeller and gage inspection forms are specified in references (A), (B) and (D). A summary listing is included below:

NSWCCD-SSES or Contracting Activity

Attached to Propeller/Gage

Propeller Visual, reference (H) Propeller Dimensional, reference (I) Propeller Certification, reference (J) Blade Gage Visual, reference (K) Blade Gage Dimensional, reference (L) Blade Gage Certification, reference (M) Plug and Ring Gage Visual, reference (B)

X X X X X X

2-2

Plug and Ring Gage Certification, reference (B)

X X

2-3

CHAPTER 3

PROPELLER TERMINOLOGY

3-1 TERMINOLOGY

The following definitions apply to propeller terminology. The terminology may vary with some propeller drawings.

3-1.1 BLADE CENTER AXIS (BCA). Most often a straight line with an origin at the propeller centerline (PCL) that is intersected by the pitch line of each cylindrical section (Figures 3-1, and 3-2). The BCA may be displaced axially from the PCA, and this displacement describes the rake of the blade (Figures 3-3 and 3-4). If the rake is nonlinear this will be reflected with a nonlinear BCA.

3-1.2 BLADE CENTERLINE (BCL). A line for each blade that intersects the pitch line of each cylindrical section at the midpoint of the blade section width. It establishes the skew of each cylindrical section (Figures 3-2, 3-4, and 3-5).

3-1.3 BLADE NUMBERING. A sequential numbering of blades. For ahead rotation, the first blade to pass the side eyebolt hole location is blade number 1. The numbering sequence is opposite from the direction of rotation (Figure 3-6). Some controllable pitch propeller blades may have an opposite sequential numbering system; refer to the propeller blade manufacturing drawing if in doubt. If no eyebolt holes are present use the narrow keyway as a reference; for controllable pitch propeller blades use hub/blade palm stamping.

3-1.4 BLADE SECTION HALF WIDTH. Distance from the blade section centerline to the leading edge (LE) ordinate or trailing edge (TE) ordinate (Figure 3-5).

3-1.5 BLADE SECTION WIDTH. The distance from the leading edge to the trailing edge along the pitch line. This is sometimes referred to as blade section length. The blade section width is divided into increments of 10 percent or less to define the blade section contour adequately (Figure 3-7).

3-1.6 CYLINDRICAL CENTER ELEMENT (CCE). The axial projection of the blade center axis (BCA) at a cylindrical section (Figure 3-5).

3-1.7 CYLINDRICAL SECTION (BLADE SECTION). The cross section of a blade cut by a circular cylinder whose axis coincides with the propeller's axis of rotation (Figure 3-5).

3-1.8 CYLINDRICAL SECTION STATIONS. These are located at percentage increments of the blade cylindrical section width and are used to define section pressure and suction face contours (Figure 3-7).

3-1

3-1.9 FILLETS. The transition from the blade surfaces and edges to the propeller hub periphery.

Usually fillets are constructed with compound radii faired into blade surface and hub contours (figure 3-8).

3-1.10 LEADING EDGE (LE). The edge of a propeller blade adjacent to the forward end of the hub.

3-1.11 LEADING EDGE ORDINATE. The point at which the suction face and pressure face meet at the leading edge.

3-1.12 LEFT HAND PROPELLER. A propeller which rotates in the counterclockwise direction, looking forward, for ahead propulsion. A left hand propeller is usually a port propeller, but there are exceptions to this convention.

3-1.13 OFFSETS. The perpendicular distances, from the blade section pitch line to the blade surfaces, that define the contours of the pressure and suction faces (figure 3-5) and thickness. Offsets are defined on the propeller drawing in the Table of Section Offsets.

3-1.14 PITCH. The theoretical distance, parallel to the axis of rotation, that each design section advances in one complete revolution (figure 3-9). The pitch may be the same at all design radii (i.e., constant pitch) or may vary from hub to tip (i.e., variable pitch) (figure 3-10). Controllable pitch propellers have individual blades mounted on a hub. By means of a control and actuator system, the blades can be pivoted about an axis effecting a pitch change while the shaft is rotating.

3-1.15 PITCH ANGLE. The angle between the pitch line and a plane perpendicular to the propeller centerline (figure 3-11).

3-1.16 PITCH LINE (PL). A line for each cylindrical section extending from the leading edge to the trailing edge, but not necessarily passing through the extremities…